Carb Rebuild
by Timothy William Beynart

OK, you have the carbs off the bike now. First of all, make sure you have a well lit, clean, organized work bench. Have a divided tray or four little boxes or something to divide the pieces up as you take the carbs apart. One approach is to take only one carb body apart at a time, but I'm too impatient for that and your problem sounds like it exists between carb bodies.

Anyway, have a #1 and #2 Philips head handy. Have a bucket of carb cleaner or better yet kerosene with a basket for retrieving the goods. You might as well thoroughly clean the carbs while you have them apart. Use rubber gloves while you handle all the carbs and cleaner, and make sure the area is ventilated.

I'm getting ahead of myself, so back to the bench. You have a nice clean space with a nice clean towel/rag laid out and your carbs sitting in front of you. before you do anything, you gotta to relax and commit to the task ahead. For me, this means Loritabs or Darvocets. You gotta stay sharp, so lay off the kind bud, and alcohol is a big no-no. Now that you're primed, take a sharp object or Dremel tool and etch a number on each float bowl and carb top and the carb body. The point is to match everything up when you reassemble, and any ink or paint won't survive the carb cleaning. I take the float bowls off first. Flip over your carbs so the float bowls are facing up. Unscrew a bowl, and carefully remove it. You may need to really reef on it to get the seal to pop, but avoid prying it with a screwdriver 'cause you may damage the gasket. Take the float out and be real careful about small parts, especially the pin that the float levers on. Once my carbs were totally screwing up and it was due to one of these pins being bent. Also, there is a plastic ding-dong attached to the float. Don't lose this. Don't lose anything. Don't drop anything. Here is where your tray with dividers in it really comes into it's own. I'm superstitious about replacing parts exactly where they came from, so label the trays. If you're installing a jet kit, here is where you'd put in the new jet. It's obvious: the thing in the middle.

Now you can take off the vacuum diaphram cover (the other side of the carb). Pay attention here, because as you loosen that last screw and take the cover off a big spring will shoot out and you're screwed is you lose it. I've spent long, tense afternoons on all fours shuffling around for one of these goddam things. Then again, I've had many long, perverted afternoons on all fours that I enjoyed immensely... So you pulled out the spring and now you have a rubber dish-looking thing. Again, be real real careful here because this part costs $83. It is the diaphram that holds the needle. Gently loosen an edge and lift it out. Needless to say, inspect this baby for cracks and whatnot, but be especially mindful of storage and when you reassmble the carbs it is critical that you don't botch this part. The gasket end of the diaphram has a tab on it to line up correctly, so there's no excuse for pinching this part.Clean the needles if they look gunky, but be careful not to scar them.

That's pretty much it. Before you drop your carbs in the cleaner, make sure you've removed all the rubber gaskets. I've never had to deal with the problem you described, and it may require disconnecting the carbs from one another, which I haven't done and which no sane person would attempt. Seriously, if you do need to move the carbs around pay close attention to the linkage and all the teeny springs. If you blow it, say your prayers...

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